Method of sealing panelized curtain wall assembly



April 9, 1963 c. c. CIPRIANI ETAL METHOD OF SEALING PANELIZED CURTAIN WALL ASSEMBLY Filed NOV. 5, 1958 5 Sheets-Sheet 1 %//V/ Mg/ //%Q7 5/ @WRNEVF April 1963 c. c. CIPRIANI ETAL 3,034,483

METHOD OF SEALING PANELIZED CURTAIN WALL ASSEMBLY Filed Nov. 3, 1958 v 3 Sheets-Sheet 3 ATToQMEVs United States Patent 3,684,433 METHQD 0F SEALING PANELIZED CURTAIN WALL ASSEMBLY Chester C. Cipriani, Toledo, and Charles H. Stark, Waterville, Ohio, assignors, by mesne assignments, to Owens- Illinois Glass Company, Toledo, ()hio, a corporation of ()hio Filed Nov. 3, 1958, Ser. No. 771,283 3 Qlaims. (Cl. 50-203) The present invention relates to wall structures and more particularly to a method of sealing curtain wall structures comprised of prefabricated panels containing structural hollow glass blocks or cells, other light-transmitting materials, or opaque sheets of building materials.

The invention broadly relates to the field of constructing buildings and more specifically to weatherproofing a curtain wall construction such as that disclosed in our copending patent application, Serial No. 760,3 65, now Patent No. 2,996,845 filed September 11, 1958, entitled Structural Panel and Building Wall Construction Utilizing Same, this application being assigned to the same assignee as the present application. The referred to application describes fully and completely a novel and improved curtain wall assembly formed of prefabricated panel units having similar peripheral contours which are readily erectable in situ in tiered edgewise relation to form exterior and interior surfaces of a building wall.

In most forms of curtain wall construction adapted to light transmission and particularly those which have heretofore employed hollow glass building blocks, the prevention of water and water vapor penetration and interior collection of moisture due to internal condensation have presented serious problems diflicult of solution in practice. Previously, a fully weather-tight panelized exterior wall sealed against water, wind and moisture penetration has been considered virtually unobtainable in commercial production of curtain wall assemblies utilizing conventional glass blocks, for example. Where such seals have been temporarily obtained in economically competitive panelized structures, it has been observed that such constructions do not and are not expected to withstand water and moisture penetration permanently or for any lengthy period due to inherent tendencies of the building walls to settle irregularly and ultimately crack. Furthermore, a wall comprised of panel units utilizing metallic framing members must be fully capable of conjunctive movement without separation of panel joints to permit thermal expansion and contraction of the wall throughout the temperature range of the particular climate in which the building is located and throughout the life of the wall. Not to provide for thermal expansivity throughout widespread temperature variation of from -20 F. to 110 F. for the temperate latitudes, for example, permits joints between adjacent panels to gradually open to the atmosphere allowing the entrance of the elements to efiect adversely the wall and interior conditions and to result ultimately in destruction of the wall. The inherent problems in providing adequate gasketing between rigid prefabricated panel units erected into tiered edgewise relation to form a curtain wall have necessitated the present invention. Previously the prior art has offered little more than conventional commercial caulking materials which provide weather-tight scaling for only relatively brief periods of time and require periodic replacement for the wall to retain its weather-resistant effectiveness. Also many caulking materials are unable to permit expansivity of the wall joints without loss of weatherseal.

Accordingly, it is an object of the present invention to provide a novel and improved methtod of sealing a plurality of preformed panel units to furnish a fully Weathertight wall.

Another object of this invention is to provide a unique method of gasketing interconnecting perimeters of similarly framed structural panel units to ensure complete weather sealing against most severe weather conditions and over extensive periods of time.

A further object of this invention is to provide a method of weatherproofing a curtain wall assembly fabricated of a plurality of rectangular similarly framed prefarbricated structural panels stacked in edgewise vertical arrangement and retained in erected relation by spaced-apart vertical struts disposed either interiorly or exteriorly of the building wall.

A still further object of the present invention is to provide a method of durably gasketing one or both sides of horizontal and vertical joints between interconnecting perimeters of preformed structural panels by utilizing lineal strips of elastomeric material having substantially different durometer hardnesses to seal the joints with one being capable of conforming to the other in areas of overlapping contact at corners of adjacent panels.

The specific nature of this invention, as well as other objects and advantages thereof, will become apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheet of drawings on which, by way of preferred example only, are illustrated the preferred embodiments of this invention.

On the accompanying drawings:

FIG. 1 is .an elevational view of a building wall illustrating one embodiment of the present invention in sealing a curtain wall assembly providing both interior and exterior wall surfaces.

FIG. 2 is a top plan view of the curtain wall assembly taken along the line 22 of FIG. 1.

FIG. 3 is an enlarged fragmentary vertical sectional View taken along the line 3--3 of FIG. 1 illustrating a horizontal joint between similar adjacent panels containing hollow glass blocks.

FIG. 4 is a fragmentary horizontal sectional view taken along the line 4-4 of FIG. 1 illustrating a vertical joint between adjacent similar panels.

FIG. 5 is a fragmentary horizontal sectional view taken along the line 5-5 of FIG. 1 illustrating the panel retention and gasketing arrangement at interconnecting upper corners of adjacent panels.

FIG. 6 is a perspective view illustrating two similar glass block containing panels in erected form.

FIG. 7 is a fragmentary vertical sectional view taken along the line 77 of FIG. 5 further illustrating overlapping of the gasketing materials at corner areas of adjacent panels.

FIG. 8 is a further enlarged fragmentary vertical sectional view of a portion of FIG. 7 showing a single horizontal gasketing strip in disengaged relation.

FIG. 9 is a view similar to FIG. 8 showing the panel edges and gasketing materials in engaged relation.

While the present invention will be described hereinafter as specifically relating to scaling a plurality of prefabricated structural wall panels of several specific forms into a weather-tight curtain wall, it will be readily apparent to those skilled in the art that the principles of the invention are equally applicable to weather-sealing any size or shape of preformed panelized units having interconnecting peripheral frames which are adapted to erection as a permanently aligned and positively interlocking curtain wall construction.

Multi-storied buildings of the types to which preformed structural panels and curtain wall assemblies are especially applicable conventionally comprise the usual loadbearing upright columns and structural steel spandrels such as I-beams which may be encased in concrete extending between the columns for support of concrete or other types of flooring. The actual form and dimensions of the load-bearing structural elements of the building are well-known and do not specifically comprise the subject matter of this invention. This invention pertains to curtain walls and to their durable sealing wherein the wall forming panels generally hear at least a part of their own weight as erected in tiered arrangement and do not normally carry the weight of the building, its upper floors or roof, although the scope of the invention is not limited to such structures.

Referring now to the drawings and especially to FIG. 1, certain sidewall portions of the building 20 may be formed of conventional upright walls indicated by the numeral 22 which sidewalls may surround a vertical opening in an existing building or an original expanse in a new'building adapted to installation of the subject curtain wall. The curtain wall may be employed to form all or part of the original walls of a new structure or modifications to an existing structure. However, only for purposes of description is the present invention disclosed as it relates to .sealing the subject curtain wall within an opening in an existing building structure.

As illustrated in FIG. 1 a plurality of building wall panel units is employed to form a curtain wall assembly designated by the numeral 3%). The curtain wall assembly 39 fully encloses the expanse within conventional building walls 22. Curtain wall 3! is formed by a series of preformed panel units erected in tiered edgewise relationsupported by building sill 21. Sidewalls 22 and sill 21 may be comprised of conventional brick, stone, wood or other forms of building materials.

Each individual panel of the curtain Wall is formed with a rectangular metallic frame surrounding a series of spaced-apart hollow glass blocks, one or more sheets of transparent material such as window glass ,to provide fenestration, or one or more facing sheets such as porcelainized or enameled sheet metal to provide a panel unit having opaque face planes. Each panel possesses properties of being both moisture-proof and water impermeable interiorly of its metal perimeter and exhibits features of being thermally insulating due to a minimal amount of heat-conductive through metal employed in its fabrication.

Each of the panels designated by the numeral 31 contains a series of structural hollow glass blocks orcells of transparent material which have essentially square face dimensions and are light-transmitting and/ or light-directing. Each of the panels designated by the numeral 32 contains clear sheets of transparent materials such as glass or plastic while the panels designated by numeral 33 contain opaque or vitreous faced metallic sheets. The panels as to their specific construction are more fully defined in the referred to copending patent application.

As shown in FIGS, 1, 2 and 3 a series of vertical struts or mullions 34 are mounted in essentially a common vertical plane each having one wall-supporting surface. Struts 34 extend between sill 21 and an overhead portion of wall 22 near the uppermost area of curtain wall assembly 30. Each strut 34 is firmly fixed at its ends to the sill and overhead wall and is sufiiciently rigid to maintain its wall supporting surface in permanent alignment in a vertical plane with like members. Each strut 34 comprises a lengthy hollow U-shaped member such as those referred to as Unistrut having a continuous lengthwise opening 34a or recess facing its supporting surface. Struts 34 are mounted in parallel series spaced-apart a distance equivalent to the horizontal module of the similarly framed panels 31, 32 and 33 for their permanent retention in erected relation. Panels 31, 32 and 33 are mounted in stacked edge-to-edge arrangement fastened against the supporting faces of the struts 34. While only one strut 34 is shown in the drawings for purposes of describing this invention, the referred to application discloses their use in parallel series throughout a lengthy horizontal expanse.

Struts 34 may all be disposed in like relationship either interior or exterior of the wall with their supporting surfaces coplanar adapted to engage the stacked panel units. Alternately some of the struts 34 may be disposed interiorly and others exteriorly of the wall to engage inner and outer wall surfaces respectively. It is necessary only that one strut 34 be disposed in vertical alignment with each vertical joint between adjacent panels in side-by-side relationship for their permanent retention. Any desired alternating arrangement of struts 34 may be employed on one or both sides of the wall to enhance the appearance of the curtain wall assembly 30 and to achieve distinctive architectural effects. The supporting surface of each strut 34 is placed in alignment with either the inner or outer surface of the vertical joint. Struts 34 serve to retain the erected series of panels 31, 32 and 33 in upright tiered relation by fastening elements engageable therewith which penetrate their longitudinal openings. The fastening elements are preferably disposed at intersecting corners of adjacent panels. Struts 34 also serve to seal one side of the vertical joints by carrying intermediate lineal strips of gasketing material against which the panel edges are retained.

Lineal batten elements 35 which also carry resilient gasketing material to further weatherproof the vertical joints between adjacent side-by-side panels are arranged on the opposite side of the panel joints from each individual strut 34 as shown in FIGS. 2 and 3. Batten elements 35 which are employed in conjunction with supporting struts 34 are disposed either interiorly or exteriorly of the building in opposing relation from the vertical struts to seal the particular side of the joints to which they are applied. Struts 34 have a considerably greater depth of section than batten strips 35 to perform the function of supporting the panel units 31, 32 and 33 in upright edge-to-edge relation without horizontal deflection or undue deformation of the wall during severe weather conditions and throughout the life of the wall. Batten elements 35 do not serve to retain the panels upright but to conform to and complete the sealing of the vertical joints. It may be desired in certain situations to employ two batten elements 35, one on each side of the vertical joints such as near jamb areas where curtain wall assembly 30 connects with the building Wall 22. Also each batten member 35 may be provided with a coextensive cover plate 35a.

Each of the panels 31, 32 and 33 has essentially equal dimensions and a similarly contoured peripheral metallic frame 40 of uniform thickness enclosing one form of structural materials such as a plurality of hollow glass blocks 41 having generally equal dimensions. Blocks 41 may be disposed within frame 40 in spaced-apart relation with an interconnecting grid work of solidified mortar or cementitious material 42 bonding the sides of adjacent blocks 41 to each other and to the inner surfaces of peripheral frame 40. Blocks 41 which are preferably employed within panel 31 are essentially square and have an approximate thickness of two inches which dimension is essentially half the thickness of ordinary glass blocks. The blocks may measure nearly twelve inches on a side and panel 31 may have horizontal and vertical modular dimensions of two by four feet, for example. However, it is to be understood that these dimensions are in no Way critical in practicing the present invention.

As illustrated in FIG. 3 horizontally extending framing members 45 and 46 furnish the upper and lower edge surfaces respectively of panel frame 40. Frame members 45 and 46 comprise complemental telescoping U-shaped channels each having twin right-angled flanges 45a and 46a respectively extending exteriorly. Upper frame member 45 is provided with a pair of exteriorly facing dovetailed recesses 45b arranged within and perpendicular to upstanding flanges 45a.

Two lineal strips 50 of resilient elastomeric gasketing material such as natural rubber, synthetic rubber, or plastic are retained within the dovetailed areas 45b of framing member 45 for weather sealing both sides of the horizontal joints of the wall. The strips 50 are carried by each panel being attached during its manufacture or prior to erection of the panels into a curtain wall. The strips 50 extend coextensively with the upper corner areas of each panel so that at least one surface of each strip remains in partialy exteriorly exposed relation upon joining the upper and lower edges of two panels. Strips 50 which comprise the primary elastomeric material for gasketing extend in one direction such as to seal the horizontal joints between adjacent interconnecting panels. Strip 50 preferably consist of black neoprene rubber having an A durometer hardness ranging from about 50 to 75. The material is capable of extrusion into shaped form for its retention in dovetailed area 45b as shown in FIG. 8 and having a grooved recess 50a adapted to receive the flange portion 46a of a panel disposed thereabove. Each strip 50 has an outwardly facing cylindrical segment portion 50b above groove 50a adapted to sealing against an internal surface of flange 46a. Strips 50 may be composed of neoprene or GR-S type rubber having an A durometer hardness of about 60 and being resistant to cracking due to exposure to sunlight. One form of suitable resilient material consists of black neoprene rubber manufactured by Inland Manufacturing Company, Dayton, Ohio in eX- truded form as material specification No. SC-720C.

At least one strip 50 is carried by dovetailed region 45a on an exteriorly facing corner of each panel. However, it is preferred that two strips 50 be utilized to gasket both interior and exterior surfaces of the horizontal joints.

As shown in FIG. 4 the vertical edges 43 and 44 of two similar panels 31 containing glass blocks 41 are interconnected by two opositely facing L-shaped flanges 43a and 44a respectively disposed in a medial region. The interlocking L-shaped flanges are disposed within a central region of the vertical joints and serve to retain the panels in positive connecting relation and to control their relative movement in a horizontal direction. The corner edges of panel frame members 43 and 44 are retained against the wall supporting surfaces of struts 34.

Twin strips 64 of secondary resilient gasketing material such as sponge rubber are employed on both sides of the longitudinal opening 34a provided in the strut member 34. As shown in FIG. 5, the upwardly extending horizontal flanges 45a of two adjacent interconnecting panels 31 are connected to strut 34 by a machine bolt 66 and two connecting plates 61 and 62 contacting upright flanges 45a and the interior of strut 34 respectively. When bolt 6G is drawn tight with its threaded end interconnecting with a threaded opening in cross member 62, the two lineal strips 64 of secondary gasketing material are drawn tight against the vertical edges of flange members 43 and 44 and conform thereto. The strips 64 which extend fully coextensive with strut 34 also contact and conform to the horizontal strips 54 which are considerably more firm. FIG. 5 illustrates how vertical strips 64 and 65 being comprised of softer secondary gasketing material such as sponge rubber are deformed to a greater extent than horizontal strips 50 where contacted on opposing sides of the two adjacent panels 31. Strips 64 which comprise the secondary elastomeric material for gasketing preferably consist of sponge rubber having an A durometer hardness ranging from 10 to The sponge rubber may be defined as closed-cell nitrogen-filled having a very uniform structure with its interstices filled with nitrogen gas. One form of sponge rubber adapted to practice the present invention is sold under the trade name Rubatex, closed-cell nitrogen-filled, Type 172-N, manufactured and distributed by the Rubatex Division of Great American Industries, Huntington, West Virginia.

Batten strip 35 which is attached to the opposite side of the vertical joint is connected to the upright exteriorly facing surfaces of frame members 43 and 44 as shown in FIGS. 4 and 5. Batten 35 is attached by a series of spaced machine bolts 66 extending through an opening in the batten and threaded into an internal cross-member 67. Batten member 35 also carries a lineal strip of secondary elastomeric gasketing material 65 comparable to strips 64 to conform to corner surfaces of framing members 43 and 44 and horizontal gasketing strips 50 at the intersecting corners of adjacent panels.

In practicing the present method of weather sealing joints of a curtain wall assembly 30 one or preferably two lineal strips 50 of primary elastomeric material are disposed between the horizontal peripheral flanges of stacked panels with at least one surface of each gasketing strip being exteriorly exposed. When the panel flanges are stacked in telescoping relation with the upper surface of upstanding flanges 45a supporting the panel or panels thereabove, downwardly projecting flange portion 46a penetrates the lineal groove 50a of the gasketing material (FIGS. 7 and 9) and applies a uniform compressive force thereto. The convexly curved portion 5% of the strip which faces outwardly is compressed inwardly so that a seal is effected both interiorly of the telescoping flanges as well as at the lowermost terminating portion of flange 46a. This primary horizontal elastomeric gasketing material has a durometer hardness on the A scale of about 60 and is capable of being extruded in strip form having the cross-sectional form illustrated in FIG. 8 including the dovetailed portion which is fitted into dovetailed recess 45b.

The panels are stacked in side-by-side relation in the same vertical plane held against the twin vertical strips 64 of more resilient secondary gasketing material. The upper corners of adjacent panels are attached to strut 34 by fastening member 60' utilizing its cross members 61 and 62. Bolt 60 is tightened to compress vertical flange members 43 and 44 against the secondary elastomeric material to secure its conformity thereto. At this time horizontal strips 50 are also compressed tightly against strips 64 as indicated in FIGS. 5 and 7 so that the appreciably more resilient softer vertical gasketing strips 64 are made to conform to the terminating portions of horizontal strips 50. FIG. 5 shows the harder horizontal strips 50 being forced into softer vertical strips 64 at a localized intersecting region of these elements with both types of strips being compressively deformed to some extent depending upon their relative elastic resilience. As shown in FIG. 9 the exterior lip portion of horizontal strip 50 is held against a lower exterior portion of flange 46a to seal additionally the intersection of the several gasketing materials. Thus, a durable and permanent seal is effected at the upper corner areas of each panel which is extremely weather-resistant.

The end portions of horizontal strips 50 on the opposite side of the vertical joint are also compressed by lineal strip 65 of secondary elastomeric material which contacts the horizontal strips in a manner similar to that described above. Thus, by securing conformity of the secondary elastomeric material to the panel edges and primary elastomeric material and by utilizing the secondary materiol on both sides of the vertical joints, complete and durable weather-tight sealing is obtained. The primary horizontal gasketing material has a resiliency which is 1 to 2 times less than that of the secondary vertical gasketing material. It has been found that an approximate ratio of resiliencies between the primary and secondary elastomeric materials should be 3 to l or greater with the primary material having an A durometer hardness of about 50 to and the secondary material having an A durometer hardness of about 10 to 20. The primary material may be extruded into various shapes such as the disclosed or other forms with a hardness of about 60 on A durometer scale. The secondary material is one normally incapable of extrusion consisting of flat sheets which are severed into lineal strips 7 for the vertical gasketing. The secondary material preferably has a hardness of about on the A durorneter scale.

The joints between adjacent interconnecting rectangular panels which reside in horizontal and vertical lines are fully gasketed to provide weather-tight seals. All joints are capable of excluding adverse weather conditions such as snow, rain, wind, hail and even rain driven by winds of hurricane force. The space interior of the sealed points is all interconnected extending in both vertical and horizontal directions between the series of contacting panels to provide adequate interior ventilation of the panel joints for the removal of moisture and/or water should leakage of any localized area of the curtain wall temporarily occur. Tightening of the panel retention members, i.e., bolts 60, or the batten retention members, i.e., bolts 66, or both permits resealing of the wall to its original effectiveness. Thus, the curtain Wall assembly is originally sealed against the atmosphere for long term weather resistance and may be subsequently resealed in a convenient manner.

Various modifications may be resorted to within the spirit and scope of the appended claims.

Durometer Type A relates to only a part of the hardness range of rubber and other pliable materials and specifically is adapted to measuring with extreme sensitiveness the class of materials referred to as elastic and semi-elastic rubbers and like materials. Elastic rubbers practically end at 90- hard in rating, up to which limit the A durorneter test is very sensitive. The A durorneter test and instrument is extensively used to determine the hardness of live rubbers, such as those disclosed in the present application.

We claim:

1. A building wall construction of the curtain wall type comprised of a plurality of vertically-aligned superimposed rectangular wall panels and horizontally-aligned adjacent wall panels each having similarly oriented interconnecting edges, a series of vertical and horizontal joints between said wall panels, and at least one rigid vertical member disposed in essentially coplanar alignment coextensive with the vertical joints between adjacent panels,

the improvement of a weather-tight seal between both horizontal and vertical joints formed by adjacent panel edges and said vertical member comprising at least one first lineal strip of primary elastomeric gasket material retained between interconnecting horizontal edges of vertically adjacent panels in uniform compression with at least one portion of said-first strip protruding exteriorly beyond said edges, said first strip being of lesser horizontal width than said horizontal joint, at least one second lineal strip of secondary elastomeric gasket material disposed between said interconnecting vertical panel edges and said vertical member normal to and in overlying contacting relationship to said first strip, said second strip having an elastic resilience substantially greater than said first strip, and fastening means connecting said vertical membet to said vertical panel edges for compressively retaining said second strip in sealing engagement therebetween and in physical contact with the overlapped portion of said first strip.

2. The weather-tight seal between both horizontal and vertical joints in accordance with claim 1, wherein the said second strip of secondary elastomeric gasket material has an elastic resilience at least three times greater than said first strip of primary elastomeric material.

3. The weather-tight seal between both horizontal and vertical joints in accordance with claim 1, wherein said first strip of primary elastomeric gasket material has an A durorneter hardness ranging from to and said second strip of secondary elastomeric gasket material has an A durorneter hardness ranging from 10 to 20, the latter being capable of conforming to the contour of the former when compressed thereagainst in sealing engagement.

References Cited in the file of this patent UNITED STATES PATENTS 1,958,011 Moore May 8, 1934 2,347,756 Swenson May 2, 1944 2,363,429 Lowry Nov. 21, 1944 2,769,212 Hammitt et a1 Nov. 6, 1956 2,996,845 Cipriani et al. Aug. 22, 1961 

1. A BUILDING WALL CONSTRUCTION OF THE CURTAIN WALL TYPE COMPRISED OF A PLURALITY OF VERTICALLY-ALIGNED SUPERIMPOSED RECTANGULAR WALL PANELS AND HORIZONTALLY-ALIGNED ADJACENT WALL PANELS EACH HAVING SIMILARLY ORIENTED INTERCONNECTING EDGES, A SERIES OF VERTICAL AND HORIZONTAL JOINTS BETWEEN SAID WALL PANELS, AND AT LEAST ONE RIGID VERTICAL MEMBER DISPOSED IN ESSENTIALLY COPLANAR ALIGNMENT COEXTENSIVE WITH THE VERTICAL JOINTS BETWEEN ADJACENT PANELS, THE IMPROVEMENT OF A WEATHER-TIGHT SEAL BETWEEN BOTH HORIZONTAL AND VERTICAL JOINTS FORMED BY ADJACENT PANEL EDGES AND SAID VERTICAL MEMBER COMPRISING AT LEAST ONE FIRST LINEAL STRIP OF PRIMARY ELASTOMERIC GASKET MATERIAL RETAINED BETWEEN INTERCONNECTING HORIZONTAL EDGES OF VERTICALLY ADJACENT PANELS IN UNIFORM COMPRESSION WITH AT LEAST ONE PORTION OF SAID FIRST STRIP PROTRUDING EXTERIORLY BEYOND 